1 Guidelines to Fitting Bodies CLA Edition March 2018 V1...MAN Trucks India’s technical documents...

1 Guidelines to Fitting Bodies CLA Edition March 2018 V1.0

Publisher

MAN Trucks India Pvt. Ltd.

201-216, Pride Silicon Plaza,

Beside Chatusrungi Temple,

Senapati Bapat Road, Pune-411016, India.

Tel.: +91 20 6645 2828

Website: www.mantrucksindia.com

1st edition: November 2009

2nd edition : September 2010

3rd edition : March 2013

4th edition : April 2014

5th edition : March 2016

6th edition : April 2018

Applicability of the Guide:

The guidelines given in this booklet are general in nature.

We expect the fabricators to adhere to the guidelines given in this booklet while mounting any equipment or carrying

out any modifications on our chassis if required, in general.

The best practice would be to get the final layout or modifications / changes carried out by

Fabricator to be confirmed from MAN Trucks India Applications / Technical team in order to have smooth functioning

of the overall solution provided to the end customer.

This Guide applies to:

- New vehicles

- Old vehicles - In case retro-fitment work is being carried out on these vehicles.

For further assistance or queries, please contact:

MAN Trucks India Pvt. Ltd.

Product Management Group

Tel: + 91 20 6645 2828

Fax: + 91 20 6645 2878

Edition March 2018 V1.0 Guidelines to Fitting Bodies CLA 2

1. Designation of Vehicle ............................................................................................................ 7

1.1. Model range ............................................................................................................................ 7

1.2. Wheel formula ......................................................................................................................... 7

1.3. Engine designations / variant ..................................................................................................... 8

1.4. Chassis Designation / VIN (Vehicle Identification Number) ....................................................... 10

1.4.1. VIN Plate ....................................................................................................................... 11

1.5. Gearbox, Front Axle & Rear Axle designation .......................................................................... 11

1.6. Use of logos .......................................................................................................................... 13

1.7. Cabs ..................................................................................................................................... 14

2. General ................................................................................................................................ 15

2.1. Legal agreements and approval procedure ................................................................................ 15

2.1.1. Preconditions .................................................................................................................. 15

2.2. Responsibility ........................................................................................................................ 15

2.3. Approval ............................................................................................................................... 16

2.4. Submission of documents ....................................................................................................... 16

2.5. Warranty ............................................................................................................................... 17

2.6. Liability ................................................................................................................................ 17

2.7. Limitation of liability for accessories / spare parts ..................................................................... 17

2.8. Type approval ........................................................................................................................ 18

2.9. Safety ................................................................................................................................... 18

2.9.1. Functional and operational safety ...................................................................................... 19

2.10. General technical basics ................................................................................................... 20

2.10.1. Axle overload, one-sided loading ................................................................................... 20

2.10.2. Minimum front axle load .............................................................................................. 22

2.10.3. Wheels, rolling circumference ....................................................................................... 22

2.11. Permissible overhang ....................................................................................................... 22

2.11.1. Permissible overhang .................................................................................................... 23


3. Modifying the Chassis .......................................................................................................... 26

3.1. Safety at work ....................................................................................................................... 26

3.2. Corrosion protection ............................................................................................................... 26

3.3. Frame dimensions and material ............................................................................................... 27

3.4. Subframe material .................................................................................................................. 28

3.5. Modifying the frame ............................................................................................................... 28

3.5.1. Drill holes, riveted joints and screw connections on the frame .............................................. 28

3.5.2. Cut outs in the frame ........................................................................................................ 31

3.6. Welding the frame.................................................................................................................. 32

3.6.1. Modifications to the overall vehicle (only for Export vehicles) ............................................. 34

3.6.1.1. Modifications to the wheelbase (only for Export Vehicles) ............................................... 34

3.6.1.2. Type of wheelbase modification (only for Export vehicles) .............................................. 35

3.6.1.3. Relocating the entire rear-axle unit ................................................................................. 35

3.6.1.4. Separating the frame side member ................................................................................. 36

3.6.2. Modifying the frame overhang .......................................................................................... 41

3.6.3. Wheel Base & ROH (Rear overhang) modification recommendations

(only for Export vehicles) ................................................................................................... 44

3.7. Retrofitting equipment ............................................................................................................ 45

3.8. Retrofitting of leading and trailing axles ................................................................................... 45

3.9. Propeller shafts (Prop shafts) ................................................................................................... 46

3.9.1. Single joint ..................................................................................................................... 46

3.9.2. Jointed shaft with two joints ............................................................................................. 47

3.9.3. Three dimensional propshaft layout ................................................................................... 47

3.9.4. Propshaft train ................................................................................................................. 49

3.9.4.1. Forces in the propshaft system ....................................................................................... 50

3.9.5. Modifying the propshaft layout in the driveline of MAN Trucks India chassis ....................... 50

3.10. Add on frame components ................................................................................................ 51

3.10.1. Underride guard ........................................................................................................... 51

3.10.2. Side guards .................................................................................................................. 52

3.10.3. Spare wheel ................................................................................................................. 53

3.10.4. Wheel chocks .............................................................................................................. 53

3.10.5. Fuel tanks .................................................................................................................... 53


3.11. Modifications to the engine .............................................................................................. 54

3.11.1. Air intake, exhaust gas path ........................................................................................... 54

3.11.2. AdBlue-System ............................................................................................................ 57

3.11.2.1. Basic principles and structure of the AdBlue system ........................................................ 57

3.11.2.2. AdBlue line set ............................................................................................................ 60

3.11.2.3. AdBlue tank ................................................................................................................ 63

3.11.3. Engine cooling ............................................................................................................. 64

3.11.4. Engine encapsulation, noise insulation............................................................................ 64

3.12. Fifth-wheel coupling ........................................................................................................ 65

3.12.1. Converting the vehicle type – truck / tractor .................................................................... 67

4. Bodies .................................................................................................................................. 68

4.1. General ................................................................................................................................. 68

4.1.1. Accessibility, Clearances .................................................................................................. 69

4.1.2. Lowering the body ........................................................................................................... 70

4.1.3. Platforms and steps .......................................................................................................... 70

4.1.4. Corrosion protection ........................................................................................................ 71

4.2. Subframes ............................................................................................................................. 71

4.2.1. Designing the subframe .................................................................................................... 73

4.2.1.1. Attachment plate details specific for deep mining vehicle D26 440 hp for wheel base

1850+2750+1400 (8X4) ................................................................................................ 76


1850+3175+1400 / 1850+3425+1400 (8X4)................................................................... 77


1850+3425+1400 (8X4) ................................................................................................ 78

4.2.2. Attaching Sub frames and bodies ...................................................................................... 80

4.2.2.1. Screw connections and riveted joints .............................................................................. 81

4.2.2.2. Flexible connections ..................................................................................................... 81

4.2.2.3. Rigid connections ......................................................................................................... 85

4.3. Special bodies ........................................................................................................................ 87

4.3.1. Testing of bodies ............................................................................................................. 87

4.3.2. Single pivot body ............................................................................................................ 88


4.3.3. Tank and container bodies ................................................................................................ 88

4.3.3.1. General ....................................................................................................................... 88

4.3.3.2. Body fixtures, mountings .............................................................................................. 88

4.3.4. Tippers ........................................................................................................................... 89

4.3.5. Set-down, sliding set-down and sliding roll-off skip loaders ................................................. 91

4.3.6. Platform and box bodies ................................................................................................... 92

4.3.7. Interchangeable containers ............................................................................................... 93

4.3.7.1. Factory fitted interchangeable platform chassis ............................................................... 93

4.3.7.2. Other interchangeable equipment ................................................................................... 93

4.3.8. Loading cranes ................................................................................................................ 94

4.3.8.1. Loading crane behind the cab ........................................................................................ 97

4.3.8.2. Rear loading crane........................................................................................................ 98

4.3.8.3. Subframe for loading crane ......................................................................................... 100

4.3.9. Tail-lifts ....................................................................................................................... 101

4.3.10. Cable winches ............................................................................................................ 102

4.3.11. Transit mixers ............................................................................................................ 103

5. Electricals .......................................................................................................................... 104

5.1. Introduction ......................................................................................................................... 104

5.2. References to repair workshop manuals and standards ............................................................. 104

5.3. Starting, tow-starting and operating........................................................................................ 104

5.4. Additional wiring diagrams and wiring harness drawings ......................................................... 105

5.5. Fuses, power for additional consumers ................................................................................... 105

5.6. Type of electrical conductors and relays to be used .................................................................. 105

5.7. Lightning installations .......................................................................................................... 106

5.8. Interference suppression ....................................................................................................... 107

5.9. Electromagnetic compability ................................................................................................. 107

5.10. Interfaces on the vehicle ................................................................................................. 107

5.11. Body Fittings ................................................................................................................ 108

5.12. Setting customer-specific parameters with MAN-cats ........................................................ 108

5.13. Earth Cable ................................................................................................................... 108


5.14. Installation and routing of electric cabling / Pipe work ...................................................... 109

5.15. Cables .......................................................................................................................... 110

5.15.1. Routing Cables .......................................................................................................... 110

5.15.2. Wiring harnesses for wheelbase extensions ................................................................... 111

5.15.3. Supplementary wiring diagrams and cable harness drawings ........................................... 113

5.15.4. Interfaces on the vehicle, preparations for the body ........................................................ 113

6. Brakes, Lines ..................................................................................................................... 114

6.1. Brake and compressed air lines .............................................................................................. 114

6.1.1. Basic principles ............................................................................................................. 114

6.1.2. Plug connectors, changeover to Voss 232 system .............................................................. 115

6.1.3. Installing and attaching lines ........................................................................................... 116

6.1.4. Compressed air loss ....................................................................................................... 118

6.2. Connecting ancillary consumers ............................................................................................ 119

6.3. Connecting ancillary consumers ............................................................................................ 121

7. Power Take Off´s ............................................................................................................... 122

7.1. Fundamentals ...................................................................................................................... 122

7.1.1. Calculating power and torque ......................................................................................... 123

7.1.2. Drife shaft connection to power take-off .......................................................................... 124

7.2. Power take-off on gearbox .................................................................................................... 125

7.2.1. Differentation................................................................................................................ 125

7.2.2. Clutch-dependent power take-offs ................................................................................... 126


1. Designation of Vehicle

To identify and differentiate MAN vehicles, components and assemblies, Sections 1.1 to 1.5 of this chapter will describe some

of the designations in greater detail. The figures contained in model designations serve only as an indication and are not definite

figures for actual maximum load carrying capacity for specific components or assemblies; in addition, they do not always agree

with the legal regulations.

1.1. Model range

When reference is made in this Guide to vehicle family or model range, it refers to the following vehicles: CLA – with GVW/GCW of 16t - 50t

CLA stands for CARGO LINE ASIA range vehicles which is specially made to cover India & Asia pacific region.

1.2. Wheel formula

For more accurate identification, the wheel formula can be used alongside the vehicle designation. This is a familiar, but not

standardized term. Twin tyres are regarded as one wheel, i.e. it is the ''wheel locations” that are counted. The wheel formula does

not indicate which axles are driven. On all-wheel drive vehicles, not all axles are necessarily driven; instead, it may be that all-

wheel drive components are merely present in the drive train.

Example for wheel formula: 6x4/2

6 = Number of wheel locations, in total

x = has no function

4 = Number of driven wheels

/ = only the front wheels are steered

2 = Number of steered wheels In normal parlance, the number of steered wheels is not stated if only two wheels are steered. However, for consistency,

MAN Trucks India’s technical documents do indicate the number of steered wheels.


1.3. Engine designations / variant

Diesel engines with mechanical or EDC injection from the D08 engine family are used on the

CLA (D08 = 1st – 3rd digit of the engine designation). Depending upon rated power and rated torque they are in-line four

cylinder (R4) or in-line six cylinder (R6). They are available either as Euro 2, Euro 3 or Euro 4 engines.

Table 1: CLA engines/engine designations D08 / D26 Bharat Stage 2/3/4 mechanical or with EDC

Vehicle designation

Emission class

Power [kW] / at rpm

Power [kW] / at rpm

Engine type

Engine designation

xx.180 BS III 132kW 650 Nm at 1300 – 1700 rpm R4 D0834 LFL07 VP44

xx.280 BS III 206kW 1100 Nm at 1300 – 1700 rpm R6 D0836 LFL08 Vp44

xx.220 BS II 162kW 800 Nm at 1300 – 1700 rpm R6 D0836 LFL10 VE

xx.280 BS III 206kW 1100 Nm at 1300 – 1700 rpm R6 D0836 LFL13 CR (CP3.3)

xx.220 BS III 162kW 800 Nm at 1200 – 1800 rpm R6 D0836 LFL16 Vp44

xx.220 BS III 159kW 800 Nm at 1200 – 1600 rpm R6 D0836 LFL17

xx.220 BS III 159kW 800 Nm at 1200 – 1600 rpm R6 Do836 LFL18 VE

xx.300 BS IV 223kW 1150Nm at 1200-1800rpm R6 D0836 LF20 CR

xx.400 BS IV 324kW 2200Nm at 1000-1400rpm R6 D2676 LF28


Table 2: CLA engines/engine designations D08 / D26 Bharat Stage 2/3/4 mechanical or with EDC

Engine Identification Number (EIN)

1 2 3 4 5 6 7 8 9 10 11 12 13 14

No. of Cylinder Type of fuel Model year code Month code Consecutive Number Place Holder

Cylinder Code

Code

0 0 0 0 0

4 4

6 6

8 8

Fuel Diesel

Diesel D

CNG C Model

Year Code Month Code

LPG L 2018 J January A

Petrol P 2019 K February B

2020 L March C

2021 M April D

2022 N May E

2023 P June F

July G

August H

September J

October K

November L

December M


1.4. Chassis Designation / VIN (Vehicle Identification Number)

MAN Trucks India is following international standard to designate the vehicle chassis.

Table 3: Chassis Designation

1 2 3 4 5 6 7 8 9 10 11 1

2

1

3

1

4

1

5

1

6

17

M B K M A 1 L Z C 7 N X X X X X X

World

manu-

facturer‘s

Model

code

Month Code Vehicle

config.

Check

digit

Model

Year

Assem

bly

line

code

Consecutive Number

Identifier MA5 January A

CLA

18.280

4x2

BBS(R6)

February B Code Model

Year

Code

MC5

CLA

26.280

6x4

BB(R6)

March C 2003 3

April D 2004 4

May E 2005 5

June F 2006 6

July G 2007 7

August H 2008 8

September J 2009 9

October K 2010 A

November L 2011 B

December M 2012 C


1.4.1. VIN Plate

The VIN-plate is bolted in the door folding on driver side. It contains the following information (type approval number depends on the country where vehicle is type approved):

1.5. Gearbox, Front Axle & Rear Axle designation

Gearbox:

Fig 1 VIN-Plate

Fig 2: Gearbox designation


Front Axle:

Fig 3 Front Axle designation

Rear Axle:

Fig 4 Rear Axle designation

1.6. Use of logos

MAN logos on the chassis must not be removed or modified in any way without prior approval by MAN Trucks India Pvt. Ltd. Modifications to the chassis or body that do not conform with this Guide for body mounting and that have not received an

approval by MAN Trucks India department (for address see “Publisher” above) must receive a new vehicle identification number

(VIN) from the manufacturer responsible for the modification (normally the body building company). In such cases where the chassis/vehicle has received a new VIN, the logos on the radiator grille (MAN Trucks India lettering, lion emblem) and the doors

must be removed.


1.7. Cabs

CLA chassis are supplied with the following cab variants / cab designations:

Table 4: CLA cabs

Dimensions* (in mm) Views

Name Length Width Height

(from Cab -0 to top)

Side Front

Day

Cabin 1.520 2.200

1.588

Flat Roof

Sleeper

Cabin

1.820 1.588

* Inside dimensions of cabin


2. General

2.1. Legal agreements and approval procedure

National regulations must be adhered to. The company carrying out the work remains responsible even after the vehicle has been approved if the authorities responsible issue an approval unaware of the operational safety of the product.

2.1.1. Preconditions

In addition to this Guide, the company carrying out the work must observe all

Laws and decrees

Accident prevention regulations

Operating instructions

relating to the operation and construction of the vehicle. Standards are technical standards; they are therefore minimum

requirements. Anyone who does not endeavour to observe these minimum requirements is regarded as operating negligently.

Standards are binding when they form part of regulations.

For certain types of equipment, such as loading cranes, tail-lifts, and cable winches etc, the respective manufacturers have

developed their own body regulations. If, when compared with this MAN Guide, they impose further conditions, then these too

must be observed.

References to

legal stipulations

accident prevention regulations

decrees from professional associations

work regulations

other guidelines and sources of information

are not in any way complete and are only intended as ideas for further information. They do not replace the company's obligation

to carry out its own checks.

Fuel consumption is considerably affected by modifications to the vehicle, by the mounted body and its design and by the

operation of equipment driven by the vehicle's engine. It is therefore expected that the company carrying out the work implements

a design that facilitates the lowest possible fuel consumption.

2.2. Responsibility

The responsibility for proper

Design

Production

Installation of bodies

Modification to the chassis

always lies fully with the company that is manufacturing the body, installing it or carrying out modifications (manufacturer's

liability). This also applies if MAN Trucks India has expressly approved the body or the modification. Bodies/conversions that

have been approved in writing by MAN Trucks India do not release the body manufacturer from his responsibility for the product.


2.3. Approval

Approval from MAN Trucks India for a body or a chassis modification is not required if the bodies or modifications are being carried out in accordance with this Guide. If MAN Truck India approves a body or a chassis modification, this approval refers

- In the case of bodies only to the body's fundamental compatibility with the respective chassis and the interfaces to the body (e.g. dimensions and mounting of the subframe)

- In the case of chassis modifications only to the fact that, from a design point of view, the modifications to the chassis in question are fundamentally permissible. The approval note that MAN Trucks India enters on the submitted technical documents does not indicate a check on the

function

Design

Equipment of the body or the modification

Observance of this Guide does not free the user from responsibility to perform modifications and manufacture bodies properly

from a technical point of view. The approval observations only refer to such measures or components as are to be found in the

submitted technical documents.

MAN Trucks India reserves the right to refuse to issue approvals for bodies or modifications, even if a comparable approval has

already been issued. Later submissions for approval are not automatically treated the same as earlier ones, because technical

advances achieved in the interim period have to be taken into account.

MAN Trucks India also reserves the right to change this Guide at any time or to issue instructions that differ from this Guide for

individual chassis.

2.4. Submission of documents

Documents should only be sent to MAN TRUCKS INDIA PVT. LTD if bodies/conversions diverge from this guide. Before

work begins on the vehicle, technical documents that require approval or inspection must be sent to MAN TRUCKS INDIA

PVT. LTD. Chassis Drawings, data sheets etc. can also be requested from this office.

For an approval process to proceed swiftly, the following are required:

Documents should be submitted in duplicate, at the very least

The number of individual documents should be kept to a minimum

All the technical data and documents must be submitted.

The following information should be included:

Vehicle model (see chapter 2.2 model code) with

Cab design

Wheelbase

Frame overhang

Length of rear overhang (vehicle overhang)

Vehicle identification number

Vehicle Number

Dimensions from the centre of the body to the centre of the last axle

Centre of gravity position of the payload and body

Body dimensions

Material and dimensions of the subframe that is to be used

Body mountings on the chassis frame


Description of any deviations from this "MAN Trucks India Guide for body mounting on Trucks"

Any references to identical or similar vehicles

Some types of bodies, such as loading cranes, cable winches etc., necessitate information specific to their type.

In the documents submitted, all main length dimensions must be stated with respect to the wheel centre of the first axle, as appropriate.

Drawings are only valid if they bear the number that has been assigned to them. It is therefore not permitted to draw in the bodies

or modifications on chassis drawings that have been provided by MAN Truck India and to submit these for approval.

2.5. Warranty

Warranty claims only exist within the frameworks of the purchasing contract between bayer and seller. In accordance with this,

the warranty obligation lies with the respective seller of the goods.

Warranty claims against MAN Trucks India are not valid if the fault that is the subjectof the complaint was due to the fact that:

This Guide was not observed

Inview of the purpose for which the vehicle is used, an unsuitable chassis has been selected

The damage to the chassis has been caused by

o The body

o The type of body mounting or how the body has been mounted

o The modification to the chassis

o Improper use.

2.6. Liability

Any faults in the work that are identified by MAN Trucks India are to be corrected. In so far as is legally permissible, MAN Trucks India disclaims all liability, in particular for consequential damage. Product liability regulates:

The liability of the manufacturer for its products or component

The compensation claim made by the manufacturer against whom a claim has been made against the manufacturer of

an integral component, if the damage that has occurred is due to a fault in that component

The company that has made the body or carried out the modification is to relieve MAN TRUCKS INDIA PVT. LTD of any

liability to its customer or other third party if the damage that has occurred is due to the fact that

The company did not observe this Guide

The body or chassis modification has caused damage on account of its faulty

Design

Manufacture

Installation

instructions

The fundamental rules that are laid down have not been complied with in any other way.

2.7. Limitation of liability for accessories / spare parts

Accessories and spare parts that MAN Trucks India has not manufactured or approved for use in its products may affect the traffic safety and operational safety of the vehicle and create hazardous situations. MAN Trucks India (or the seller) accepts no

liability for claims of any kind resulting from a combination of the vehicle together with an accessory that was made by another manufacturer, regardless of whether MAN Trucks India (or the seller) has sold the accessory itself or fitted it to the vehicle (or

the subject of the contract).


2.8. Type approval

Each vehicle that is to be used on the road must be officially approved. Approval is carried out by the local Vehicle Licensing

Agency after submission of the vehicle documentation.

ARAI Approval (Automotive Research Association of India)

The vehicle documentation is drawn up by a technical agency, vehicle manufacturer and / or chassis manufacturer after the

vehicle has been examined.

CIRT, VRDE, ICAT are some of the agencies which can be approached in consultation with MAN Trucks India.

Modifications that affect the certification may only be added by the official agency responsible. Expiry of the certification will

also cancel insurance cover.

The responsible authorities, the officially recognized expert, the customer or a MAN Trucks India department may request

submission of a drawing bearing the MAN Trucks India approval mark; in some circumstances, evidence in the form of

calculations or the submission of this Guide may suffice.

2.9. Safety

Companies carrying out work on the chassis/vehicle are liable for any damage that may be caused by poor functional and operational safety or inadequate operating instructions. Therefore, MAN Trucks India requires the body manufacturer or vehicle conversion company to:

Ensure the highest possible safety, in line with the state of the art

Provide comprehensible, sufficient operating instructions

Provide permanent, easily visible instruction plates on hazardous points for operators and/or third parties

Observe the necessary protection measures (e.g. fire and explosion prevention)

Provide full toxicological information

Provide full environmental information


2.9.1. Functional and operational safety

Safety is top priority! All available technical means of avoiding incidents that will undermine operational safety are to be

implemented. This applies equally to:

Active safety = prevention of accidents. This includes:

Driving safety achieved by the overall vehicle design, including the body

Safety as a consequence of the driver's well-being achieved by keeping occupant stress caused by vibrations, noise, climatic conditions etc. to a minimum

Safety as a consequence of observation and perception, in particular through the correct design of lighting systems, warning equipment, providing sufficient direct and indirect visibility

Safety as a consequence of operating equipment and controls this includes optimizing the ease of operation of all equipment, including that of the body.

Passive safety = avoidance and reduction of the consequences of accidents. This includes:

Exterior safety such as the design of the outside of the vehicle and body with respect to deformation behaviour and the installation of protective devices

Interior safety including the protection of occupants of vehicles and cabs that are installed by the body builders.

Sufficient space for all parts required to carry out a movement, including all pipes and cables, must be guaranteed. For further information refer Manual for CLA trucks including operating & maintenance instructions.


2.10. General technical basics

National and international regulations take priority over technically permissible dimensions and weights if they limit the

technically permissible dimensions and weights. To achieve optimum payload carrying capability the chassis must be weighed

before work starts on the body. Calculations can then be made to determine the best centre of gravity position for payload and

body as well as the optimum body length. As a result of component tolerances the weight of the standard chassis is allowed to

vary by ± 5%.

Changes in equipment may result in deviations in the dimensions and weights, particularly if different tyres are fitted then that also leads to a change in the permissible loads. In each individual case when a body is fitted care needs to be taken to ensure the following:

Under no circumstances may the permissible axle weights be exceeded

A sufficient minimum front axle load is achieved

The position of the centre of gravity and loading must not be one-sided

The permissible overhang (vehicle overhang) is not exceeded.

2.10.1. Axle overload, one-sided loading

Fig 5 Overloading the front axle

Fig 6 Difference in wheel load

Formula 1 Difference in wheel load

The body must be designed such that one-sided wheel loads do not occur. Following checks, a maximum wheel load difference

of 5% is permitted (where 100% represents the actual axle load and not the permissible axle load).


Example:

Actual axle load Gtat = 6.000kg

Therefore, the permissible wheel load difference is:

ΔG = 0.05 Gtat = 0.05 6.000kg

ΔG = 300kg

This means the wheel load on one side is 2,850kg and 3,150kg on the other. The calculated maximum wheel load provides no

information on the permissible individual wheel load for the tyres fitted. Information on this can be found in the technical manuals

supplied by the tyre manufacturers.


2.10.2. Minimum front axle load

In order to maintain steerability, the stipulated front axle load must be ensured under all vehicle conditions,

see table 5.

Fig 7 Minimum front axle load

Table 5: Minimum front axle loading for any load condition as a % of the respective actual vehicle weight

Model Range Wheel Formula GVW Other Rear Load e.g.

Cranes, tail-lift

CLA 4x2 16 t 30 %

6x4 25 t 25 %

These values are inclusive of any additional rear loads such as:

• Loading cranes on the rear of the vehicle

• Tail lifts

• Transportable fork lift trucks

2.10.3. Wheels, rolling circumference

Different tyre sizes on the front and rear axle(s) can only be fitted if the difference in rolling circumference of the tyres used does

not exceed 10%, max. 2% are permissible for all wheel drive vehicles (currently not available in the CLA range).

The notes in Chapter 4.1.1 “Body” relating to anti-skid chains, load rating and clearance must be observed.

2.11. Permissible overhang

The theoretical overhang (vehicle overhang including body) is the measurement from the resulting rear axle centre (determined by the theoretical wheelbase) to the end of the vehicle. For definition, see diagrams in the following section 2.12. The following maximum values are permitted, expressed as a percentage of the theoretical wheelbase

• For all vehicles 60% *for latest updates please refer CMVR


2.11.1. Permissible overhang

The theoretical wheelbase is an aid for calculating the position of the centre of gravity and the axle loads. It is defined in the

following diagrams. Warning: the effective wheelbase on turns that is used to calculate the turning circles is not in every case

identical to the theoretical wheelbase considered for calculating the weight.

Fig 8 Theoretical wheelbase and overhand - two axle vehicle

Formula 2 Theoretical wheelbase for a two axle vehicle

Formula 3 Permissible overhang for a two axle vehicle

Fig 9 Theoretical wheelbase and overhang for a three-axle vehicle with two rear axles and identical rear axle loads


Formula 4: Theoretical wheelbase for a three-axle vehicle with two rear axles and identical rear axle loads

lt = l12 +0.5 l23

Formula 5: Permissible overhang for a three-axle vehicle with two rear axles and identical rear axle loads

ut ≤ 0.60 lt

Fig 10 Theoretical wheelbase and overhang for a three-axle vehicle with two rear axles and different rear axle loads (in the MAN

Trucks India vehicle Range, e.g. all 6x2/2, 6x2/4, and 6/2-4

Formula 6: Theoretical wheelbase for a three-axle vehicle with two rear axles and different rear axle loads

lt = L12 + (l23)

2

Formula 7: Permissible overhang for a three-axle vehicle with two rear axles and different rear axle loads

ut < = 0.60 lt


Fig 11 Theoretical wheelbase and overhang for a four-axle vehicle with two front and two rear axles

(any load axle distribution)

Formula 8: Theoretical wheelbase for a four-axle vehicle with two front and two rear axles (any axle load distribution

lt = l12 + l23 + 0.5 l34

Formula 9: Permissible overhang for a four-axle vehicle with two front and two rear axles

ut < = 0.60 lt


3. Modifying the Chassis

To provide customers with the products they want, additional components sometimes need to be installed, attached or modified. For uniformity of design and ease of maintenance, we recommend that original MAN Trucks components be used whenever this is in accordance with the vehicle's design and ratings. MAN Trucks India will advise on the installation of additional components. To keep maintenance work as low as possible, we recommend using components that have the same maintenance intervals as

the MAN Trucks chassis. If necessary, consult component manufacturers regarding the co-ordination of maintenance intervals

and obtain their consent.

3.1. Safety at work

Accident prevention regulations must be observed, in particular:

Do not breathe in any harmful gases/fumes, such as exhaust gas, harmful substances released during welding or fumes

from cleaning agents and solvents; extract them from the work area using suitable equipment.

Secure the vehicle to prevent it from rolling.

Make safe any equipment when removing it

3.2. Corrosion protection

Surface and corrosion protection affects the service life and appearance of the product. In general, the quality of the coatings on body components should be equal to that of the chassis. To ensure this requirement is met, the MAN Works Standard M 3297 “Corrosion protection and coating systems for non-MAN bodies” is binding for bodies that are ordered by MAN Trucks India. If the customer commissions the body, this standard is highly recommended. Should the standard not be observed, MAN Trucks India provides no guarantee for any consequences. Series production chassis are coated with environmentally friendly, water-based 2-component chassis top-coat paints at approx. 80°C. To guarantee uniform coating, the following coating structure is required for all metal component assemblies on the body and subframe:

Bare metal or blasted component surface (SA 2.5)

Primer coat: 2-component epoxy primer or, if possible cathodic dip painting with zinc phosphate pre-treatment Top coat: 2-component top-coat, preferably water-based; if there are no facilities for this, then solvent-based

paint is also permitted

Instead of priming and painting with a top coat, the substructure of the body (e.g. longitudinal and cross-members, corner plates)

may also be galvanised with a layer thickness ≥ 80μm. See the relevant paint manufacturer's data sheets for information on

tolerances for drying and curing times and temperatures. When selecting and combining materials the compatibility of the

different metals (e.g. aluminium and steel) must be taken into consideration as must the effects of the 'electrochemical series'

(cause of contact corrosion).


After all work on the chassis has been completed:

Remove any drilling swarf

Remove burrs from the edges

Apply wax preservative to any cavities

Mechanical connections (e.g. bolts, nuts, washers, pins) that have not been painted over must be given optimum corrosion protection. To prevent the occurrence of salt corrosion whilst the vehicle is stationary during the body building phase, all chassis must be washed with clean water to remove any salt residues as soon as they arrive at the body manufacturer's premises.

3.3. Frame dimensions and material

For the CLA D08 / D26 the following longitudinal frame member is used:

Fig 12 Profile data for longitudinal frame members CLA

Model H

mm h

mm Bo

mm Bu

mm t

mm R

mm G

kg/m σ0,2

N/mm2 σB

N/mm2 A

mm2 ex

mm ey

mm Ix

cm4 Wx1

cm3 Wx2

cm3 Iy

cm4 Wy1

cm3 Wy2

cm3

CLA 270 256 80 80 7 10 22 460 490-627 2831 18 135 2770 205 205 150 83 24

D26 270 251 85 85 9.5 10 22 460 490-627 3883 20 135 3993 295 295 240 120 37

Steel quality is BSK 46.

The frame mounting is either a straight or cranked ladder frame. The smaller rear frame mounting of the cranked frame is for the

MAN planetary-axles.

Bo


3.4. Subframe material

The subframe must be made of steel. For reasons of strength materials with yield point σ0.2 < 235 N/mm2

are not allowed at all. Materials with yield point σ0.2 ≥ 235 N/mm2 and ≤ 350 N/mm2 are only suitable for use to a limited degree.

They are therefore only permitted for subframe longitudinal and cross members that are subject only to line loads from the body.

Should point loads arise or if auxiliary equipment is to be fitted that exerts localised forces, then steels with a yield point of σ0.2

> 350 N/mm² must always be used.

D26 440 hp Engine Vehicle body Sub frame material strength with yield should be min. 460 N/mm2.

3.5. Modifying the frame

3.5.1. Drill holes, riveted joints and screw connections on the frame

If possible, use the holes already drilled in the frame. No drilling should be carried out in the flanges of the frame longitudinal

member profiles, i.e. in the upper and lower flanges (see Fig. 10). The only exception to this is at the rear end of the frame,

outside the area of all the parts fitted to the frame that have a load-bearing function for the rearmost axle (see Fig. 15).

This also applies to the subframe.

It is possible to drill holes along the entire usable length of the frame (see Fig. 16). However, the permissible distances between

holes must be adhered to as illustrated in Fig. 17.

After drilling, rub down all holes and remove any burrs.

Several frame components and add-on components (e.g. corner plates with cross member, shear plates, platform corner pieces)

are riveted to the frame during production. If modification to these components is required at a later time then bolted connections

with a minimum strength class of 10.9 and mechanical keeper are permitted. MAN Trucks India recommends double nip

countersunk bolts/nuts. The manufacturer's stipulated tightening torque must be adhered to.

If double nip countersunk bolts are reinstalled then new bolts/nuts must be used on the tightening side. The tightening side can

be recognized by slight marks on the bolt's nips or nut flange (see Fig. 13).

Fig 13 Marks on the bolt's nips on the tightening side

Alternatively, it is possible to use high-strength rivets; manufacturers' installation instructions must be followed. The riveted

joint must be at least equivalent to the screw connection in terms of design and strength.


Fig 14 Frame drill holes in the upper and lower flange

Fig 15 Drill holes at frame end


Fig 16 Drill holes along the entire length of the frame

Fig 17 Distances between drill holes

ØD=15mm


3.5.2. Cut outs in the frame

No cut-outs may be made on the frame longitudinal and cross members (see Fig. 18).

The function of the frame cross members must not be adversely affected. Therefore cut-outs are not permitted and drill holes

and openings are only permitted to a limited extent. For examples, see Figs. 19 and 20.

Under no circumstances make openings or drill holes in cross members made of tubular profile sections.

Fig 18 Cut-outs on the frame

Fig 19 Making an opening at

the top of the frame cross member

Fig 20 Making an opening at the bottom of the frame cross member


3.6. Welding the frame

Welders must have specialist knowledge in chassis welding. The workshop must therefore employ suitably trained and qualified

personnel to carry out the required welding work.

No welding work is permitted on the frame and axle mounting components other than that approved by MAN Trucks India.

Welding work on components that are subject to design approval (e.g. coupling devices) may only be carried out by the design

approval holder – normally the manufacturer or importer.

The frames of MAN Trucks India commercial vehicles are made from high-strength fine-grain steels. The fine-grain steels used

during manufacture are well suited to welding. Performed by a qualified welder, the MAG (metal-active gas) and MMA (manual

metal arc) welding methods ensure high quality, long lasting welded joints.

Recommended welding materials:

MAG SG 3 welding wire

MMA B 10 electrode

It is important to prepare the area of the weld thoroughly before welding so that a high-quality joint can be achieved.

Heat-sensitive parts must be protected or removed. The areas where the part to be welded joins the vehicle and the earth terminal

on the welding equipment must be bare; therefore any paint, corrosion, oil, grease, dirt, etc., must be removed. Only direct current

welding may be employed; note the polarity of the electrodes.

Fig 20 Protecting heat-sensitive parts like plastic tubes

Pipes/wires (air, electric) around the area of the weld must be protected against heat. It is better to remove them completely.

Do not carry out any welding if the ambient temperature falls below +5°C.


No undercuts are to be made whilst carrying out welding work (see fillet welds, Fig. 21). Cracks in the weld seam are not permitted. Joint seams on the longitudinal members are to be made as X or Y seams in several passes (see Fig. 22). Vertical welds should be carried out from bottom to top (see Fig.23).

Fig 21 Undercuts

Fig 22 Welding an X and Y seam

Fig 23 Vertical welds on the frame


To prevent damage to electronic assemblies (e.g. alternator, radio, ABS, EDC, ECAS) adhere to the following procedure:

Disconnect the battery positive and negative leads; join the loose ends of the cables together (- with +)

Turn on the battery master switch (mechanical switch) or bypass the electric battery master switch on the solenoid

(disconnect cables and join together)

Attach the earth clip of the welding equipment directly to the area to be welded, ensuring there is good conductivity

If two parts are to be welded together connect them together first, ensuring good conductivity (e.g. connect both parts

to the earth clip)

Electronic components and assemblies do not have to be disconnected if the above-mentioned requirements are followed

3.6.1. Modifications to the overall vehicle (only for Export vehicles)

Important: The following procedures described are only applicable for export vehicles!

3.6.1.1. Modifications to the wheelbase (only for Export Vehicles)


Every change of wheelbase requires manufacturer’s confirmation. It is assumed that any change to the wheelbase will only be

carried out subsequent to receipt of the manufacturer’s approval.

Notes on applying for manufacturer’s confirmation can be found in Chapter 2, Section 2.3 and Section 2.4.

As a basic principle, it must be ensured that the new wheelbase is within the model limit. “Within the model limit”

Means that the new wheelbase is neither

shorter than the shortest nor

longer than the longest

Standard wheelbase for the same model of vehicle.

The same model of vehicle” means vehicles with

the same model number

the same type of vehicle and

the same wheel configuration

Any shortening or extending of wheelbases exceeding this may only be carried out by MAN or its qualified conversion suppliers

(“qUL”) subsequent to consultation with MAN.


3.6.1.2. Type of wheelbase modification (only for Export vehicles)


Modifications to the wheelbase can be carried out in one of the following two ways:

I. Relocating the entire rear-axle unit

II. Disconnecting the frame side members (inserting or removing a section of the frame).

Irrespective of the type of wheelbase modification, the following must be observed:

The maximum distance between cross members subsequent to wheelbase modification may not exceed 1500 mm. A

tolerance of +100 mm is permissible.

Modifications to the propshaft train must be carried out according to these guidelines to fitting bodies (see Chapter 3,

Section 3.9 and the instructions provided by the propshaft manufacturer. If the new wheelbase is the same as a standard

wheelbase, then the arrangement of the propshaft and cross members must be the same as that for a vehicle with standard

wheelbase.

Chapter 6, Sections 6.1.3 and Chapter 5, Section 5.15 apply with regards to the relocation of air and electrical lines.

During wheelbase extensions all rear-axle related control units and sensors must be relocated with the axle.

3.6.1.3. Relocating the entire rear-axle unit

If the rear-axle unit is relocated, the axle mounting, axle guide and cross members must be attached using rivets or MAN double-

nip countersunk bolts in accordance with Chapter 3, Section 3.5.1 of the MAN guidelines to fitting bodies. The distance between

drill holes specified there must be adhered to!

In the case of vehicles with dropped frames, the axle guide and suspension (e.g. spring hangers, longitudinal control arm brackets)

may not be located in the area in front of or within the bends in the frame. A minimum clearance of 100 mm to the second frame

bend is assumed (see Fig. 25).

Fig 24 Forbidden zone for rear axle guide


3.6.1.4. Separating the frame side member

If the wheelbase modification is carried out by separating the frame side member, it is mandatory for welding to comply with

the specifications in the MAN guidelines to fitting bodies (see Chapter 3, Section 3.6). The original frame material must be used

for any part inserted in the frame, e.g. frame side members, frame inserts. The material specifications can be found in Chapter 3,

Section 3.3 & 3.4. It is recommended that the frame side members are Pre-heated to 150°C – 200°C.

The frame must not be separated in the vicinity of:

Axle guides and suspension (e.g. spring hangers, trailing arm mountings), minimum distance 100 mm

Bends in the frame, minimum distance 100 mm

Points where loads are introduced

Gearbox mountings and cross members (also transfer cases on all-wheel-drive vehicles)

Engine mounting

Points where loads are introduced from bodywork

On vehicles with straight frames behind the cab, the area in which weld seams for wheelbase modifications are permitted begins

100 mm behind the gearbox cross member and ends 100 mm ahead of the front most rear-axle guide (see Fig. 26).

On vehicles with dropped frames behind the cab, the area in which weld seams for wheelbase modifications are permitted

begins 100 mm behind the bend and ends 100 mm ahead of the front most rear-axle guide (see Fig. 26).

Welded seams along the longitudinal axis of the vehicle are not permitted!

Fig 25 Permissible area for welding dropped frames


Fig 26 Permissible area for welding straight frames

If the wheelbase modification is carried out by separating the frame side member, weld seams for shortened wheelbases must be

secured by means of inserts. Frame inserts must be in accordance with the following:

Fig 27 Inserts for wheelbase shortening

1) Frame insert 2) Frame side member


Fig 28 Inserts for wheelbase extension

1) Frame insert 2) Frame side member 3) Profile section

Location no. 1), Fig 28 and Fig. 29:

Existing drill holes in the frame in the vicinity of the angle inserts are to be used. The following applies to the

arrangement of drill holes on the frame side member: distance between holes ≥ 50 mm, edge distances ≥ 25 mm. The

hole pattern can be found in the corresponding frame side member drawing.


Where parts are in contact, the weld seam must be leveled (no.2 in Fig. 28 and Fig 29).

Weld seam as per assessment group BS, DIN 8563, Part 3


Where wheelbases are extended by means of inserting a frame side member profile, the material specifications as set

down in the frame-section table and the maximum permissible wheelbases as per the MAN guidelines to fitting bodies

must be observed. The frame track may not be changed. If the maximum distances between frame cross members is

exceeded, supplementary cross members must be inserted.


Moreover, the following notes on the dimensions of inserts must be observed:

Fig 30 Inserts for wheelbase extension

Key:

Height (h) ≥ Width (a)

Width (a) is the same as the inner width of the frame (b), tolerance -5 mm.

Thickness is the same as frame thickness, tolerance -1 mm. Material min. Fe410 as per IS: 5986.

Rolled sections are not permitted.

On some long-wheelbase chassis, frame inserts are already fitted between the front and rear axles at the factory. Frame inserts

may not be welded together with the frame side members. This can be avoided for example, by inserting a copper-based

separating foil which is removed once the welding work is completed.

Inserts used in changing the wheelbase may be simply butted-up to one another and may either be welded together or joined with

an overlapping plate (see Fig 31, Fig 32).

Fig 31 Insert covering, outside and inside


The joint between the frame and the insert seam may not coincide with a weld seam in the frame – a distance of 100 mm

between seams must be observed.

This is easy to achieve if during cutting of the frame the location of the frame-insert joint is already taken into account.

Fig 32 Projecting inserts, outside and inside


3.6.2. Modifying the frame overhang

When the rear overhang is modified, the centre of gravity of the payload and the body shifts and as a result the axle loads change.

Only an axle load calculation can show whether this is within the permissible range. Such a calculation is therefore essential and

must be carried out before beginning the work.

If the frame overhang is to be extended, the profile section to be welded on must be of a similar material quality to the original

frame longitudinal members.

Extending the overhang with several profile sections is not permitted. If the overhang has already been extended, the frame

longitudinal member is to be removed right back to its original length. The overhang is then to be extended by the required

amount by attaching a new profile section of the appropriate length (see Fig. 33).

Wiring harnesses with appropriate fittings are available from MAN Trucks India for frame extensions. They can be obtained

from the spare parts service. Only wiring harnesses with so-called seal connectors are permitted. Observe the instructions in the

"Electrics, wiring" chapter regarding cable routing.

Fig 33 Extending the frame overhang


If it is intended to extend vehicles with short overhangs, the existing cross member between the rear spring hangers must be left

in place.

An additional frame cross member must be fitted if the distance between the cross members is more than 1,500 mm (see Fig.

34). A tolerance of +100 mm is permitted. There must always be an end cross member fitted.

Fig 34 Max. Distance between frame cross members

If both the frame overhang and the subframe are being extended at the same time, the weld seams or connection points must be

at least 100 mm apart with the subframe weld seam being located forward of the frame weld seam (see Fig. 35).

Fig 35 Extending the frame and the subframe

Even if a frame overhang has been extended the standard trailer load remains the same. When the frame overhang is shortened,

the largest possible technical trailer load is possible.


The rear end of the frame may be tapered as in Fig. 36 the resulting reduced cross-section of the longitudinal frame member

profile must still be of sufficient strength. No tapers are allowed in the vicinity of the axle locating parts.

Fig 36Tapered Frame end

The rear ends of the chassis and body longitudinal members must be closed up with suitable coverings. Suitable coverings are,

for example, metal plates or caps of rubber or suitable plastics. This does not apply to body longitudinal members if they are set

back or protected by the respective cross member or other suitable constructions.


3.6.3. Wheel Base & ROH (Rear overhang) modification recommendations (only for Export vehicles)


For modifications in existing chassis wheelbase & rear overhang Table 6: Wheel Base & ROH

Configuration to be used. Refer section 2.11 for permissible rear overhang

Table 6: Wheel Base & ROH

CLA Export

Variant

Existing CLA Wheelbase / ROH Recommended

Wheelbase Chassis Rear

Overhang

Proposed possible Wheelbase Proposed Possible Rear Overhang

Min. Max Min. Max.

4x2 Truck - Hub

Reduction Axle 4200

1050 to 2100 to

2170 3600 5200 1050 2600

4x2 Truck - Hypoid Axle

5200 2170 to 2600 3600 (5200) 1050 2600

4x2 T/H- Hub

Reduction Axle 3600 960 NO CHANGE RECOMMENDED

6x4 Truck - Hub

Reduction Axle

3175+1400 900 to 1300 ( 3175+1400 ) 4600+1400 900 2600

3825+1400 1300 3175+1400 4600+1400 900 2600

4600+1400 2600 3175+1400 (4600+1400) 900 2600

6x4 Truck - Hypoid Axle

5900+1430 3115 4200+1430 (5900+1430) 1095 3115

6x4 T/H - Hub

Reduction Axle 3175+1400 725 NO CHANGE RECOMMENDED

6x4 TIPPER- Hub Reduction Axle

3175+1400 900 (3175+1400) 3825 +1400 900 1095

3825 +1400 900 3175+1400 (3825 +1400) 900 1095

6x4 TIPPER-

Hypoid Axle 4200+1430 1095 3175+1430 (4200+1430) 900 1095

6x2 Truck- Hypoid Axle

5900+1430 3115 4200+1430 (5900+1430) 1095 3115

8x4 Tipper- Hub

Reduction Axle

1850+2750+1400 900 (1850+2750+1400) (2100+3425+1400) 900 1500

1850+3175+1400 900 1850+2750+1400 (2100+3425+1400) 900 1500

2100+3425+1400 1500 1850+2750+1400 (2100+3425+1400) 900 1500

Note- ( ) - Represents Standard Wheelbase for the same model of vehicle

Distance between two mechanical steered axles to be considered only 1850 or 2100 only. Inbetween distance not permitted


3.7. Retrofitting equipment

The manufacturer of the equipment must obtain MAN Trucks India’s agreement regarding its installation. MAN Trucks India’s

approval must be made available to the workshop carrying out the work. The workshop is obliged to request MAN Trucks India’s

approval from the equipment manufacturer. If there is no approval, then it is the responsibility of the equipment manufacturer

and not the workshop carrying out the work, to obtain it.

Under no circumstances does MAN Trucks India accept responsibility for the design or for the consequences of non-approved

retrofitted equipment. The conditions stated in this Guide and in the approvals must be followed. Only under these conditions

will MAN Trucks India accept warranty for its share of the delivery. The body manufacturer is responsible for the parts that he

supplies, for carrying out the work and for any possible consequences. As part of his supervision obligations, the body

manufacturer is also responsible for other companies working on his behalf.

An approval procedure must include documents which contain a sufficient amount of technical data and which it is possible to

inspect. Such documents include approvals, test reports and other similar documents that have been drawn up by the authorities

or other institutions.

Approvals, reports and clearance certificates that have been compiled by third parties (e.g. ICAT, CIRT, authorities, test

Institutes) do not automatically mean that MAN Trucks India will also issue approval. MAN Trucks India can refuse approval

even though third parties have issued clearance certificates.

Unless otherwise agreed, approval only refers to the actual installation of the equipment. Approval does not mean that MAN

Trucks India has checked the entire system with regard to strength, driving performance etc., or has accepted warranty. The

responsibility for this lies with the company carrying out the work, since the end product is not comparable with any MAN

Trucks India’s production vehicle. Retrofitting of equipment may change the vehicle's technical data. The equipment

manufacturer and/or the company carrying out the work is responsible for calculating and issuing this new data, e.g. for obtaining

data for subframe dimensioning or the fitting of tail-lifts and loading cranes.

Adequate service and operating instructions must be provided. We recommend co-ordinating the maintenance intervals for the

equipment with those for the vehicle.

3.8. Retrofitting of leading and trailing axles

The installation of additional axles and the repositioning of steerable front axles together with the removal of axles is not

permitted. Such conversions will be carried out by MAN Trucks India with suppliers.


3.9. Propeller shafts (Prop shafts)

Jointed shafts located in areas where people walk or work must be encased or covered.

3.9.1. Single joint

When a single cardan joint, universal joint or ball joint is rotated uniformly whilst bent it results in a non-uniform movement on the output side (see Fig. 37). This non-uniformity is often referred to as cardan error. The cardan error causes sinusoidal-like fluctuations in rotational speed on the output side. The output shaft leads and trails the input shaft. The output torque of the

propshaft fluctuates in line with this, despite constant input torque and input power.

Fig 29 Single joint

Because acceleration and deceleration occur twice during each revolution, this type of propshaft and layout cannot be permitted

for attachment to a power take-off. A single joint is feasible only if it can be proven without doubt that because of the

mass moment of inertia

rotational speed and

the angle of deflection

The vibrations and loads are not significant.


3.9.2. Jointed shaft with two joints

The non-uniformity of the single joint can be compensated for by combining two single joints in one propshaft. However, full

compensation of the movement can be achieved only if the following conditions are met:

Both joints have the same working angle, i.e. β1 = β2

The two inner yokes of the joint must be in the same plane

The input and output shafts must also be in the same plane see Figs. 38 and 39.

All three conditions must always be met simultaneously so that the cardan error can be compensated for. These conditions exist

in the so-called Z and W arrangements (see Figs. 38 and 39). The common working plane that exists for Z or W arrangements

may be freely rotated about the longitudinal axis.

The exception is the three-dimensional propshaft layout, see Fig. 32.

Fig 38 W propshaft layout Fig 39 Z Propshaft layout

3.9.3. Three dimensional propshaft layout

If the input and output shafts are not in the same plane the layout is three-dimensional. The centre lines of the input and output

shafts are not parallel. There is no common plane and therefore, to compensate for the fluctuations in angular velocity, the inner

yokes (forks) of the joint must be offset

by angle 'γ' (Gamma) - see Fig. 40.

Fig 40 Three dimensional propshaft layout


The condition that the resulting working angle ßR1 on the input shaft must be exactly the same as the working angle ßR2 on the

output shaft still applies. Therefore:

ßR1 = ßR2.

Where:

ßR1 = three-dimensional angle of shaft 1

ßR2 = three-dimensional angle of shaft 2

Three-dimensional working angle ßR is a function of the vertical and horizontal angle of the propshafts and is calculated as:

Formula 10: Three dimensional working angle

tan bR=tan bv+tan bh

The required angle of offset g can be calculated using the joint angles in the horizontal and vertical planes as follows:

Formula 11: Angle of offset

tan g1= tan bh1

; tan g1= tan bh1

; g=g1+g2 tan bv1 tan bv1

Where:

bR=Three-dimensional working angle

bV=Vertical working angle

bh=Horizontal working angle

g= Angle of offset

Note:

In the case of three-dimensional offset of a propshaft with two joints only the three-dimensional working angles need to be equal.

In theory therefore, an infinite number of layout options can be achieved from the combination of the vertical and horizontal

working angles.

We recommend that the manufacturers' advice be sought for determining the angle of offset of a three-dimensional propshaft

layout.


3.9.4. Propshaft train

If the design dictates that greater lengths have to be spanned, propshaft systems comprising two or more shafts may be used. Fig.

41 shows three basic forms of propshaft system in which the position of the joints and the drivers with respect to each other were

assumed to be arbitrary. Drive dogs and joints are to be matched to each other for kinematic reasons. Propshaft manufacturers

should be consulted when designing the system.

Fig 41 Propshaft train


3.9.4.1. Forces in the propshaft system

The joint angles in propshaft systems inevitably introduce additional forces and moments. If telescoping propshaft is extended

or compressed whilst under load further additional forces will be introduced.

Dismantling the propshaft, twisting the two halves of the shaft and then putting them back together again will not compensate

for the imbalances; it is more likely to exacerbate the problem. Such "trial and error" may cause damage to the propshafts, the

bearings, the joint, the splined shaft profile and assemblies. It is therefore essential that the markings on the propshaft are

observed. The marks must therefore be aligned when the joints are fitted (see Fig. 42).

Fig 42 Marking on propshaft

Do not remove existing balancing plates and do not confuse propshaft parts, otherwise imbalances will occur again. If one of the

balancing plates is lost or propshaft parts are replaced, the propshaft should be re-balanced. Despite careful design of a propshaft

system, vibrations may occur that may cause damage if the cause is not eliminated. Suitable measures must be used to cure the

problem such as installing dampers, the use of constant velocity joints or changing the entire propshaft system and the mass

ratios.

3.9.5. Modifying the propshaft layout in the driveline of MAN Trucks India chassis

Body manufacturers normally modify the propshaft system when:

Installing pumps on the driveshaft flange of the power take-off.

In such cases the following must be observed:

The working angle of each cardan shaft in the driveline must be maximum 7° in each plane when loaded.

If propshafts are to be extended the entire propshaft system must be re-designed by a propshaft manufacturer.

Every propshaft must be balanced before intallation


3.10. Add on frame components

3.10.1. Underride guard

Chassis can be factory-fitted with a rear underride guard. Alternatively, rear underride guard are not installed at the factory, in which case chassis units are fitted with a so-called "non-returnable lighting bracket" for transporting them to the body manufacturer. The body manufacturer must himself then fit rear underride guard that complies with regulations.

The model number and model mark are noted on a sticker on the underride guard. The following dimensional requirements

are imposed for MAN Trucks underride guards (see also Fig. 43):

The horizontal distance between the rear edge of the underride guard and the rear edge of the vehicle (rearmost edge)

must not exceed 350 mm.

The distance between the lower edge of the underride guard and the road surface must not exceed 550 mm when the

vehicle is unladen.

Vehicles that are being transported to body manufacturers or overseas do not have to have an underride guard fitted

because a special case approval has been issued.

The body manufacturer must ensure that these requirements are adhered to because the dimensions are dependent on the body.

Fig 43 Layout of underride guard


3.10.2. Side guards

All trucks, tractor units and their trailers with a permissible gross weight of > 3.5t and a maximum design speed of more than 25

km/h must have side guards (including vehicles that, because of the design of the chassis, are regarded as the equivalent of trucks

and tractor units).

Special vehicles in this respect include in particular vehicles with side tipper bodies. This only applies if they tip to the sides and

the inner length of the body is ≤ 7.500mm. Table 7 shows which tippers need side guards and which do not.

Rear Tipper Length of tipper body = 7500 >7500

Rear tipper Yes Yes

Roll-off/set-down skip loader Yes Yes

Two-way tipper No Yes

Three-way-tipper No Yes

Table 7: Types of tippers and whether they require side guards

Vehicles intended for combined transport and vehicles suitable for off-road use are not exempt from the fitting of side guards.

If the body manufacturer is to fit side guards to the chassis, then profile sections, profile supports and installation parts are

available from MAN Trucks India in a variety of designs. They can be obtained from the spare parts service. To aid the design

process, the maximum spans and projections for which the regulations with regards to strength have been met are stipulated in a

design report (see Figs. 44 and 45). If the permissible dimensions as stated in the report are exceeded, then the body builder must

carry out a strength test.

The figures clarify only the dimensions with which the MAN Trucks side guards fulfil strength requirements. Other legal

regulations have intentionally not been mentioned because the company that is installing the side guards is responsible for

meeting these.

Fig 44 Sideguards

Fig 45 Sideguards


3.10.3. Spare wheel

The spare wheel can be mounted at the side on the frame, at the end of the frame or on the body, provided there is sufficient

space for it and the relevant national regulations permit it.

In every case, the legal regulations and directives must be observed.

The spare wheel (or spare wheel lift) must be easily accessible and simple to operate.

Adouble lock to prevent loss must be provided.

The spare wheel lift is to be secured to prevent it from being lost; observe instructions in Section 3.5.1 "Rivet joints and screw connections" (e.g. mechanical keeper, double nip countersunk bolts/nuts.)

Aminimum clearance of ≥200mm from the exhaust system must be observed; if a heat shield is installed, this clearance may be ≥100mm.

If a spare wheel is fitted at the end of the frame, the reduced rear overhang angle must be noted. The location of the spare wheel

must not result in interruptions in the subframes or in their being bent at right angles or bent out to the side.

3.10.4. Wheel chocks

1 wheel chock on:

Vehicles with a permissible gross weight of more than 4 t

Two-axle trailers – apart from semitrailers and rigid drawbar trailers (including central-axle trailers) with a permissible gross weight of more than 750kg.

2 wheel chocks on:

Three and multi-axle vehicles

Semitrailers

Rigid drawbar trailers (including central-axle trailers) with a permissible gross weight of more than 750kg. Chocks must be safe to handle and sufficiently effective. They must be fitted in or on the vehicle by means of holders and must be easily accessible. The holders must prevent them from being lost and from rattling. Hooks or chains must not be used as holders.

3.10.5. Fuel tanks

If space permits, fuel tanks can be either repositioned and/or additional fuel tanks can be fitted. However, the wheel loads should be as even as possible (see Chapter 2 "General"), where possible the fuel tanks are to be mounted opposite each other, i.e. on the left and right-hand sides on the frame. It is also possible to lower the tanks. If the ground clearance is affected by shifting a fuel tank, then a guard must be fitted to prevent damage to the fuel tank.

Fuel pipes are to be routed properly, see also "Electrics, wiring" booklet. The prevailing temperatures in the areas that the vehicle will be used must be taken into account. Operation at low temperatures requires the fuel return line to be located immediately next to the intake area. This warms the intake area and is an effective means of preventing fuel from clouding (flocculation of paraffin).


3.11. Modifications to the engine

3.11.1. Air intake, exhaust gas path

There must be a free and unhindered flow of intake air and exhaust gases. The vacuum condition in the intake pipe and the backpressure in the exhaust system must not be allowed to change. Therefore observe the following points when carrying out modifications to the air intake system and/or exhaust gas path:

Never change the shape or area of cross-sections.

The radius of any bends must be at least double the diameter of the pipe.

Continuous bends only, i.e. no mitre cuts.

MAN Trucks India cannot provide information about changes in fuel consumption or noise performance; in some circumstances a new noise approval will be required.

Heat-sensitive parts (e.g. pipes, spare wheels) must be at least ≥200mm away from the exhaust; if heat shields are fitted, this clearance may be ≥100mm.

In general, modifications to the exhaust system are to be avoided. Various factory options are available for the CLA and body

builders should check to see if these can be used. Information on availability for the corresponding vehicle can be obtained

from your closest MAN sales branch.

If it is still not possible to avoid making modifications the following requirements must be met:

The outflow of exhaust gases must not be inhibited in any way.

The backpressure in the exhaust must not be allowed to vary.

All statutory regulations relevant to noise and emissions must be fulfilled.

When modifications are made to the exhaust system and routin

1 Guidelines to Fitting Bodies CLA Edition March 2018 V1...MAN Trucks India’s technical documents...

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